Weather sealed door-frame construction and method of fabrication



Dec. 19, 1967 R. R. SAHM WEATHER SEALED DOOR-FRAME CONSTRUCTION AND METHOD OF FABRICATION Filed March 5. 1966 m W N E V W Four/v0 United States Patent 3,358,402 WEATHER SEALED DOOR-FRAME CONSTRUC- TION AND METHOD OF FABRICATION Roland R. Sahm, Palos Verdes Estates, Calif assignor to Broadway Metals & Fabricators, Ine., Gardeua, Calif.,

a corporation of California Filed Mar. 3, 1966, Ser. No. 531,517 12 Claims. ((3. 49-401) This application relates to weather sealed door-frame constructions and, more particularly, to an improved door which is capable of such sealing and to a method of fabricating the same and to an improved door framework and door frame which cooperate when the door is in a closed position to accomplish highly effective weather sealing.

Diflicult sealing problems are encountered about the perimeter of exterior doors, such as are commonly used on house trailers and the like. Such doors are frequently exposed to high wind, driving rain and other severe weather conditions. In addition, it is often desirable to maintain large temperature differentials across them. Needless to say, air drafts and water leakage between mating surfaces of the door framework and surrounding frame are highly undesirable.

Considerable effort has been directed in the past to providing a door-frame construction of the subject type which is effective in establishing a good seal. For the most part, the results have been unsatisfactory for varions reasons, including failure to provide adequate sealing and costs being prohibitive. In the latter connection, it will be appreciated that sealing problems can be reduced by resort to precision manufacturing procedures involving manufacture to close tolerances, closely controlled inspection and testing and the like. However, such procedures are inherently quite expensive and, therefore, this expedient is an unsatisfactory one.

Thus it will be readily appreciated that there is a real need for an effectively weather sealed door-frame construction capable of being mass produced at low cost.

Exterior doors for use on house trailers and the like usually embody a core of wood and a rectangular metal framework at the perimeter of the core made up of a pair of stiles at the side edges and rails at the top and bottom edges. This core and framework assembly is then faced on at least its exterior side by sheet metal. The opening for the door, on the other hand, is provided with a frame having side and head jambs and a sill or threshold. A sealing member carried by one of the door framework or the frame is arranged to abut surfaces on the other of them When the door is in a closed position for the intended purpose of establishing a weather seal.

It is to be noted at the outset that the present invention is concerned with the construction of an improved door of this type and, in particular, with the structural relationship between metal surfacing and a peripheral framework embodying a sealing strip and to a method of fabricating the same. In addition, it concerns the structure and cooperative association of an element forming this door framework and an element forming an associated frame installed in the door opening, these parts cooperating when the door is in a closed position to establish a highly effective weather seal.

In view of the foregoing, it is a primary object of the invention to provide an improved weather sealed doorframe construction.

A more specific object is to provide an improved door capable of use with a door frame to establish a highly effective weather seal.

Another object is to provide an improved door of the type described further characterized in that it may be mass produced at low cost.

3,358,402 Patented Dec. 19, 1967 It is a related object of the invention to provide a method of fabricating such an improved door at low cost.

A further object is to provide an improved door-frame construction in which the door framework and associated frame cooperate when the door is in a closed position to achieve highly effective weather sealing.

A still further object is to provide an improved doorframe construction of the type described which in no way impairs easy opening and closing of the door.

Still another object is to provide an improved doorframe construction capable of accomplishing all of the foregoing objects yet which is neat and attractive in appearance and strong and durable in construction.

These and other objects, features and advantages of the invention will be better understood by referring to the following detailed description taken in conjunction with the accompanying drawing, in which:

FIG. 1 is a fragmentary perspective view of a typical installation including a portion of a door and an associated frame, both constructed in accordance with the invention;

FIG. 2 is a fragmentary sectional view on an enlarged scale taken along the line 22 of FIG. 1;

FIG. 3 is a sectional view illustrating a member used in forming the framework of the door in the condition in which it is furnished prior to use in fabricating a door by the method of the invention; and

FIGS. 4 and 5 depict successive steps of the method of fabricating the door of the invention.

Referring to FIGS. 1 and 2, a typical installation of the door-frame construction of the invention may be seen to include a rectangular frame 10 and a correspondingly shaped door 12 hingedly mounted on the frame by a plurality of spaced apart hinges 14 for swinging movement about a vertical axis. The frame 10, in turn, is supported in a wall including a supporting structure 16, exterior and interior paneling 18 and20, and trim 22. As is apparent, the supporting structure 16 is shaped to define a buck or rough frame for mounting the finished frame 10.

The frame 10, as illustrated in FIG. 1, is made up of a head jamb 24, side jambs 26, and a threshold (not shown). Each of these frame components comprises an appropriate length of a frame element 2-8 of uniform cross-section illustrated in FIG. 2. Preferably, to enhance strength and appearance, the abutting ends of the side jambs 26 and head jamb 24 and threshold are mitered and secured together as by welding.

As may be seen in FIG. 2, the door 12 comprises a flat, rectangular core 30 made of a strong material that resists flexing and is a good insulator, such as wood, mounting at its perimeter a framework 32. The latter is sized and shaped so as to be receivable in fairly close fitting relationship within the frame 10 when the door 12 is in its closed position of FIGS. 1 and 2. This core-framework assembly 30, 32 is covered on the exterior side of the door 12 by a sheet metal facing 34 secured at its marginal edges 36 in interlocked relationship with the framework 32.

The framework 32, similar to the frame 10, comprises four lengths of an element 38 of substantially uniform cross-section. Two of these lengths serve as stiles (FIG. 2) and the other two as top and bottom rails. Preferably the stiles and rails are also joined at their abutting ends, as by welding, so that the resulting framework 32 is a unitary structure.

In order to accomplish the desired weather sealing, the elements 28 and 38 embody sealing strips 29 and 39, respectively, formed of a resilient, flexible sealing material. In the closed position of the door 12, these strips sealingly engage correspondingly shaped portions of the elements 38 and 28, respectively.

Both the elements 28 and 38 are formed primarily of a strong and durable material. Aluminum is preferred as it not only has the desired physical properties, but also may be readily formed into the desired shapes by economical forming methods, as, for example, by an extrusion process. The sealing strips 29 and 39, on the other hand, may advantageously be formed of rubbers or plastics, such as vinyls. These materials also have the advantage of being adapted to be formed economically.

Considering now the detailed construction of the door 12, reference is made to FIGS. 3 to 5, illustrating the element 38 as it is furnished prior to use, and to FIGS. 4 and 5 illustrating successive steps of the method of fabricating the door 12. The element 38 may be seen to comprise an edge plate 40 of a width greater than the thickness of the core and adapted to be positioned in covering relationship with the core edge 42. A plurality of spaced apart and longitudinally extending ribs 44 are provided on the interior side of the plate for the purpose of insuring good solid contact of the element 38 with the associated core edge 42 and spacing the plate slightly away from that edge in order to facilitate installation.

This element 38 of the door framework 32 also has an integral, relatively short lip 46 at one end of the plate 40 that cooperates with the frame element 28 to effect sealing when the door 12 is in a closed position. The lip 46 overlaps slightly the outer side of the plate 40 and projects generally inwardly and forwardly at an acute angle. It is adapted to be positioned with its terminal end abutting the interior side of the core 30, as illustrated in FIGS. 4 and 5.

At the end of the plate 40 opposite the lip 46 are a pair of retainer flanges 52 and 54. These flanges 52 and 54 support a sealing strip 39 and, in the final condition of FIG. 5, grip the strip and the marginal edge 36 of the facing 34 between them. In this manner, the sealing strip 39 and the facing 34 are maintained in assembly with the framework 32. The retainer flanges 5'2 and 54, like the lip 46, are short in relation to the width of the plate 49 and they project outwardly in a direction opposite the lip 46. The forward or exterior flange '54 projects at substantially a right angle to the plate 40 and is adapted to be positioned with its exterior surface aligned flush with the exterior side of the core 30. On the other hand, the rearward or interior flange 52 has its base end disposed at slight spacing from the flange 54 and initially projects outwardly and rearwardly at an acute angle with the adjacent surface of the plate. Thus it will be seen in FIG. 2 that the two flanges 52 and 54 initially define a V-shaped opening.

The sealing strip 39 comprises an elongated member of substantially uniform cross-section. Referring to FIG. 3, it may be seen to include'a base portion 58 with a pair of stop flanges 60 and 62 and positioned between the retainer flanges 52 and 54. The sealing strip 39 further includes a U-shaped gripper portion 64 disposed around the free end of the rearward flange 52 and an arcuate sealing cuff 66. The cuff 66 is shaped so that in its free condition of FIG. 5, it projects generally rearwardly and forwardly and then back toward the flange 52, with its terminal end stopping short of the latter. It will be observed that with this mounting arrangement, the cuff 66 is protected against damage even when the door 12 is open.

Preferably, to enhance the gripping action of the flanges 52 and 54, the rearward flange 52 is provided with a plurality of inwardly facing teeth 68. In addition, the innermost tooth 68a is arranged to cooperate with the stop flanges 60 and 62, both when the flange 52 is in its initial condition of FIG. 3 and in its final condition of FIG. 5, to retain the sealing strip 39 in assembly with the remainder of the element 38. It will be seen in FIG. 3 that in that condition, the rearward sto-p flange 60 engages behind the innermost tooth 68a, while the other stop flange 62 bows the base portion 58 of the sealing strip 39 slightly rearwardly to maintain such engagement.

By virtue of this retention function of the flanges 60 and 62 and the fact that the gripper portion 64 engages around the free end of the retainer flange 52, these portions cling to the retainer flange 52 and remain out of interference with the flange 54. By virtue of the sealing strip 39 being formed of a resilient, flexible material, assembly of the base portion 58 with the flanges 52 may be readily ac complished.

In carrying out the method of the invention in fabricating the door 12, the framework 32 is first installed on the core 30. This involves securing, as by means of screws 70, appropriate lengths of the element 33 to be respective edges 42 of the core 30. As previously noted, the element 38 is sized in relation to the core 30 so that the lip 46 engages the interior side of the core and the forward retainer flange 54 is positioned substantially flush with the exterior surface thereof. In this connection, it will be appreciated that the lip 46 serves as a convenient aid in quickly and accurately positioned the element 38. Preferably, as previously discussed, the lengths of the element 38 are secured together at the corners of the framework 32 to afford a unitary structure.

Following securing of the framework 32 to the core 30, a suitable facing 34 of sheet metal or the line is positioned over the exterior side of the core-framework assembly 30, 32. The facing 34 is sized so that each of its marginal edges 36 initially overlaps the outer end of the retainer flange 54 of its respective element 38 in the manner shown in phantom lines in FIG. 4. Thereafter, each of the edges 36 is bent back on itself around the flange 54 with its end stopping just short of the stop flange 62 on the sealing strip 39. This bending may be conveniently accomplished since at this stage the other retainer flange 52 projects at an acute angle and carries the sealing strip.

The final step of the method comprises bending the rearward retainer flange 52 from its initial position of FIGS. 3 and 4 forwardly toward the other retainer flange 54 to the parallel position illustrated in FIG. 5. The two flanges 52 and 54 are then in gripping relationship, with the base portion 58 of the sealing strip 39 and the associated marginal edge 36 of the facing 34 securely gripped or interlocked between them. In the final condition of FIG. 5, not only does the stop flange 60 engage behind the innermost tooth 68a but the other stop flange 62 is behind the terminal end of the facing 34. Therefore, the sealing strip 39 is securely locked in assembly with the retainer flanges 52 and 54. This bending step completes the fabrication of the door 12 and it stands ready to be hung in the cooperating frame 16.

Turning now to the construction of the frame element 28, it comprises an integral member having an edge plate 72 adapted to be installed within the opening in the wall structure substantially perpendicular to the interior and exterior paneling 18 and 20. In the closed position of the door 12 (FIG. 2), the plate 72 is arranged to be disposed parallel to and closely adjacent the edge plate 40 of the element 38 of the door framework 32. At the exterior end of the plate 72 on its outer side, a rabbet or groove 74 is provided for receiving in fairly close fitting relationship the assembly of the sealing strip 29 and retainer flanges 52 and 54. Adjacent the interior end of the plate 72, a Y-shaped member 76 projects inwardly a short distance for mounting the sealing strip 29. As shown in FIG. 3, the configuration of the strip-mounting member 76 is such that it defines with the adjacent surface of the plate 72 a forwardly facing groove 94 into which a portion of the strip 29 is adapted to flex.

Integral with the plate 72 of the element 28 is a rel tively narrow molding section 80 which, in turn, joins a mounting section 82. The latter is shaped to facilitate attachment to the supporting structure 16 of the wall, as well as to cooperate with the molding section 80 to facilitate attachment to the exterior paneling 20. Also formed integral with the plate 72, but at its opposite.

end adjacent the strip-mounting member 82, are a trimengaging section 84 and an outwardly projecting foot 86. As is apparent, the trim-engaging section 84 is for the purpose of enhancing the appearance of the installation. On the other hand, the foot 86 engages the supporting structure 16 of the wall and insures a solid frame mounting.

The sealing strip 29 of the element 28 is arranged to cooperate with the lip 46 on the door framework 32 in the closed position of the door for effecting sealing at that location. Similar to the sealing strip 39, the sealing strip 29 has a sealing cuff 92 of arcu'ate shape. The cuff projects from the mounting member 76 generally forwardly and outwardly, i.e., oppositely to the other sealing strip 39, and finally rearwardly back toward the groove 94. It is shaped so as to be spaced normally from the member 76 and adapted for flexing toward it upon engagement with the lip 46 on the element 38 on the door 12, with at least its terminal end actually entering the groove 94 under operative conditions. By virtue of this mounting arrangement, the cuff 92, like the cuff 66, is protected against damage.

For mounting the sealing strip 29, the member 76 is shaped to provide a groove 88 for receiving a mounting flange 90 on the sealing strip 29. The parts are maintained in assembly by forming the groove 88 with a restricted mouth and the mounting flange 90 in an I-section receivable in an interference fit within the groove 88.

Installation of the frame with appropriate lengths of the element 28 may be quickly and easily accomplished. Individual lengths are positioned with the mounting section 80 and foot 86 abutting surfaces on the supporting structure 16 of the Wall. Attachment of the element 28 to such structure is accomplished in this instance with screws 96. Referring to FIGS. 1 and 2, it may be seen that following attachment of the interior and exterior paneling 18 and 20, the attachment means, as well as the mounting section 82 and foot 86 of the element 28, are concealed from view, so that the frame 10 presents a neat and attractive appearance.

Once the frame installation is complete, the door 12 is then mounted. In the illustrative case, the hinges 14 are employed in carrying this out. Such hinges are provided with plates shaped to conform to the retainer flanges 52 and 54 on the door framework 32 and to the rabbet 74 on the element 28 of the frame 10. Sections of the sealing strip 39 of lengths corresponding to the lengths of the hinges 14 are cut away to provide space for the hinge plates.

When the door 12 is so mounted on the frame 10, it is adapted to swing outwardly from its closed position of FIGS. 1 and 2. In its closed position, the door 12 is effectively weather sealed because of the engagement of the sealing strips 39 and 29 with cooperative portions of the frame and framework elements 38 and 28, respectively. Sealing at two separate locations is provided, namely, where the sealing strip 39 on the element 38 of the door framework 32 engages the Wall surface 98 of the rabbet 74 of the frame element 28 and where the sealing strip 39 on the frame element 28 is engaged by the lip 46 on the framework element 38. The sealing cuffs 65 and 92 of the respective strips 39 and 29 are then flexed from their normal or free positions, such flexing being yieldably resisted by the resilience of the material, so that such engagement is a forceful one, thereby enhancing sealing. This resilient flexing has the further advantages of readily accommodating substantial tolerances, yieldably resisting movement of the door so as to prevent rattling, and also of cushioning the door against being slammed shut.

Besides the sealing afforded by the engagement of portions of the sealing strips 29 and 39 with cooperative portions of the elements 38 and 28, the possibility of air and water leakage between the door and frame is reduced because of the configurations of the metallic portions of the respective elements 28 and 38. In this connection, it will be seen that the retainer flanges 52 and 54 on the framework element 32 overlap a portion of the frame element 28 when received within the rabbet 74, and, in addition, the lip 46 on the framework element 38 is disposed in close proximity to the grooved mounting member 76 on the frame element 28. Because of this, the possibility of leakage is reduced, as compared with conventional door-frame constructions, and with the primary sealing accomplished by sealing strips 29 and 39, the door 12 is effectively Weather sealed.

In the illustrative case, the door-frame construction of the invention has been illustrated and described as used about the entire opening in the buck or rough framework in the wall, i.e., on all four sides. It will be understood, however, that beneficial results can be gained by using such construction on less than all sides, as, for example, on only the mating top rail and non-hinged stile of the door and on cooperating parts of the frame. In such case, improved sealing, of course, would be achieved in those particular regions.

Various other changes in the details of the construction and arrangement of the various parts will occur to those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.

I claim:

1. A door for use in a cooperating frame establishing a weather sealed closure of a frame opening, comprising:

a flat and generally rectangular core having interior and exterior sides and top and bottom and side edges at its perimeter;

an elongated framework element of substantially uniform cross-section secured to said core adjacent its perimeter along at least one of said edges, said element including a generally planar edge plate mounted with its inner side in covering relationship with the associated core edge, retainer flange means projecting outwardly from said edge plate at the end thereof adjacent the exterior side of said core and having its exterior surface aligned substantially flush with said last-mentioned side, and sealing means carried by said retainer flange means with a base portion thereof in interlocked relationship with said flange means; and

a facing covering the exterior side of said core and having its marginal edge portion in interlocked relationship with said flange means.

2. The subject matter of claim 1, wherein said flange means comprises a cooperating pair of retainer flanges in gripping relationship with one another with the marginal edge portion of said facing and the base portion of said sealing means therebetween.

3. The subject matter of claim 2, including means on at least one of said retainer flanges and on the base portion of said sealing means for securely maintaining them in assembly with one another.

4. The subject matter of claim 2, wherein said facing also covers the exterior side of the said one of said retainer flanges having its exterior side aligned substantially flush with the exterior side of said core, and has its marginal edge portion bent back around the terminal end of the said one of said retainer flanges toward said edge plate.

5. The subject matter of claim 1, wherein said edge plate is Wider than the thickness of said core so as to project on the interior side of said core, and including lip means integral with said edge plate at its opposite end projecting inwardly and toward the interior side of said core and having its terminal end in engagement with the latter.

6. The subject matter of claim 1, including a plurality of spaced apart and longitudinally extending ribs integral with the inner side of said edge plate and engaging the associated edge of the core.

7. The subject matter of claim 1, wherein said sealing means also comprises a resilient, flexible sealing cult integral with said base portion and of arcuate crosssection, said cuff normally projecting on the interior side of said retainer flange means inwardly and toward the interior side of said core.

8. In a weather sealed door-frame construction, the combination of:

an elongated framework element of substantially uniform cross-section including a generally planar, first edge plate with inner and outer sides, retainer means at one end of said plate projecting outwardly at approximately a right angle thereto, lip means at the opposite end of said plate projecting inwardly, and sealing means formed of a resilient, flexible material and carried by said retainer means on the outer side of said first edge plate and on the side of said retainer means toward said opposite end of said first edge plate; and

an elongated frame element of substantially uniform cross-section cooperable with said framework element and including a generally planar, second edge plate with inner and outer sides and adapted to be disposed with its outer side adjacent and substantially parallel to the outer side of said first edge plate, means shaped to provide a rabbet at one end of said second edge plate on the inner side thereof, mounting means projecting from said plate at the opposite end thereof and on the outer side thereof, and second sealing means formed of a resilient, flexible material and carried by said mounting means on the outer side of said second edge plate and on the side of said mounting means toward the said one end of said second plate, said first and second sealing means pressurally engaging the wall of said rabbet and said lip means, respectively, when said edge plates are disposed adjacent and substantially parallel to one another as aforesaid.

9. The subject matter of claim 8, wherein each of said first and second sealing means comprises a resilient, flexible sealing cuff of arcuate cross-section, the cuff of said first sealing means normally projecting from said retainer means at spacing therefrom generally toward said first edge plate and adapted for yieldable flexing toward and away from said retainer means and the cuff of said second sealing means normally projecting from said mounting means at spacing therefrom generally toward said second edge plate and being adapted for yieldable flexing toward and away from said mounting means.

10. The subject matter of claim 8, including a plurality of lengths of said frame element joined together to afford a rectangular frame, and a plurality of lengths of said framework element joined together to afford a cooperating door framework adapted to be hingedly mounted in said frame.

11. A method of fabricating a door, including the steps of:

providing and arranging a generally rectangular core having interior and exterior sides and top and bottom and side edges at its perimeter;

securing to the perimeter of said core a framework including an elongated frame element having an edge plate disposed in covering relationship with an associated core edge, a pair of initially spread apart retainer flanges integral with said edge plate, one of said flanges initially being adjacent the exterior side of said core and the other initially being space therefrom toward the interior side of the core and carrying with it an elongated sealing strip;

positioning over the exterior side of said core a thin,

bendable facing with its marginal edge initially projecting outwardly beyond the terminal end of the said one of said retainer flanges;

bending the marginal edge of the so positioned facing back around the terminal end of the said one of said retainer flanges into the opening between said flanges; and thereafter,

bending the retainer flanges toward and into gripping relationship with one another, with the bent marginal edge portion of said facing therebetween.

12. The subject matter of claim 11, wherein the said one of said retainer flanges projects outwardly in substantially coplanar relationship with the exterior side of said core and said other of said retainer flanges initially projects toward the interior side of said core to define with said other fiange a V-shaped opening, and wherein said final bending step comprises bending the said other of said retainer flanges toward the said one of said retainer flanges.

References Cited UNITED STATES PATENTS 2,140,844 12/ 1938 Mirus-Lenschner 49-499 2,758,682 8/1956 Shwayder 49-49O X 2,790,213 4/1957 Smith 49488 3,308,582 3/1967 Bakke 49401 X KENNETH DOWNEY, Primary Examiner. 

1. A DOOR FOR USE IN A COOPERATING FRAME ESTABLISHING A WEATHER SEALED CLOSURE OF A FRAME OPENING, COMPRISING: A FLAT AND GENERALLY RECTANGULAR CORE HAVING INTERIOR AND EXTERIOR SIDES AND TOP AND BOTTOM AND SIDE EDGES AT ITS PERIMETER; AN ELONGATED FRAMEWORK ELEMENT OF SUBSTANTIALLY UNIFORM CROSS-SECTION SECURED TO SAID CORE ADJACENT ITS PERIMETER ALONG AT LEAST ONE OF SAID EDGES, SAID ELEMENT INCLUDING A GENERALLY PLANAR EDGE PLATE MOUNTED WITH ITS INNER SIDE IN COVERING RELATIONSHIP WITH THE ASSOCIATED CORE EDGE, RETAINER FLANGE MEANS PROJECTING OUTWARDLY FROM SAID EDGE PLATE AT THE END THEREOF ADJACENT THE EXTERIOR SIDE OF SAID CORE AND HAVING ITS EXTERIOR SURFACE ALIGNED SUBSTANTIALLY FLUSH WITH SAID LAST-MENTIONED SIDE, AND SEALING MEANS CARRIED BY SAID RETAINER FLANGE MEANS WITH A BASE PORTION THEREOF IN INTERLOCKED RELATIONSHIP WITH SAID FLANGE MEANS; AND A FACING COVERING THE EXTERIOR SIDE OF SAID CORE AND HAVING ITS MARGINAL EDGE PORTION IN INTERLOCKED RELATIONSHIP WITH SAID FLANGE MEANS. 